Potting and insulation system for a concentrated coil soil stator

Abstract

An assembly for an electric machine including a core with a plurality of teeth extending radially inward from the core, the plurality of teeth defining a plurality of slots for receiving coils, a plurality of coils, each coil wrapping around a respective tooth, a separator in one of the slots including a first leg joined at an angle to a second leg for separating adjacent coils within the slot, an insert between the first leg and the second leg for at least partially filling a space between the first leg and the second leg, and a potting filling space within the slot between the separator, the plurality of coils, and the insert.

What is claimed is: 
     
       1. An assembly for an electric machine comprising:
 a core having a plurality of teeth extending radially inward from the core, the plurality of teeth defining a plurality of slots for receiving coils; 
 a plurality of coils, each coil wrapping around a respective tooth; 
 a separator in one of the slots including a first leg joined at an angle to a second leg for separating adjacent coils within the slot, wherein the first leg is connected to a second leg of an adjacent separator by a cord; 
 an insert between the first leg and the second leg for at least partially filling a space between the first leg and the second leg; and 
 a potting filling space within the slot between the separator, the plurality of coils, and the insert. 
 
     
     
       2. The system of  claim 1 , wherein the separator is “V” shaped. 
     
     
       3. The system of  claim 1 , wherein the first leg and the second leg each contact a wall of the slot. 
     
     
       4. The method of  claim 1 , wherein the separator is electrically isolating. 
     
     
       5. The system of  claim 1 , wherein the insert is deformable. 
     
     
       6. The system of  claim 1 , wherein the insert includes aramid felt. 
     
     
       7. The system of  claim 1 , wherein the insert assumes a shape of the space. 
     
     
       8. The system of  claim 1 , wherein the insert includes a thermal sensor. 
     
     
       9. The system of  claim 1 , wherein the potting includes epoxy. 
     
     
       10. The system of  claim 1 , wherein the separator and the insert absorb a portion of the potting. 
     
     
       11. The system of  claim 1 , wherein a first side of the first leg contacts the coils and a second side of the first leg contacts the insert. 
     
     
       12. The system of  claim 1 , wherein a liner covers a wall of the slot. 
     
     
       13. The system of  claim 1 , wherein each of the plurality of slots includes a separator, an insert, and a potting. 
     
     
       14. An assembly for an electric machine comprising:
 a core having a plurality of teeth extending radially inward from the core, the plurality of teeth defining a plurality of slots for receiving coils; 
 a plurality of coils, each coil wrapping around a tooth; 
 a deformable “V” shaped separator including a first leg joined at an angle to a second leg for separating adjacent coils; 
 a deformable insert between the first leg and the second leg for expanding a space between the first leg and the second leg, wherein the first leg is connected to a second leg of an adjacent separator by a cord; 
 a thermal sensor located within the deformable insert; and 
 an epoxy potting covering the plurality of coils, and being absorbed by the deformable “V” shaped separator and the deformable insert. 
 
     
     
       15. A method for insulating coils comprising:
 placing a separator including a first leg joined at an angle to a second leg in a slot between adjacent teeth and adjacent coils forming a space between the legs of the separator and a wall of an electric machine; 
 inserting an insert into the space; 
 potting the coils, the separator, and the insert and 
 
       connecting the first leg to a second leg of an adjacent separator by a cord. 
     
     
       16. The method of  claim 15 , wherein epoxy is used for potting. 
     
     
       17. The method of  claim 16 , wherein the separator and the insert are saturated with epoxy.